INSTALLATION, USE AND MAINTENANCE MANUAL

Transcription

1 INSTALLATION, USE AND MAINTENANCE MANUAL SCOPE OF THIS MANUAL SERIES H DIRECT EPANSION AND CHILLED WATER AIR CONDITIONERS www. tecnairlv. it tecnairlv. it TECNAIR LV S.p.A Via Caduti della Liberazione UBOLDO (VA) Tel / Fax VERSIONE ORIGINALE

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3 CONTENTS 1 HOW TO USE THIS MANUAL IMPORTANT WARNINGS 5 2 WARRANTY 6 3 DESCRIPTION OF THE UNIT UNIT CODE OPERATING LIMITS 8 4 INSTALLATION PROCEDURE TRANSPORTATION RECEIVING THE MACHINES ON SITE POSITIONING THE UNIT AND CLEARANCES SHOCK-ABSORBING FEET RAIN CANOPY WATER CONNECTIONS CONDENSATE DRAIN AND SIPHONS WATER-COOLED CONDENSERS WATER COILS HEAT RECOVERY CIRCUIT INTERNAL ELECTRODE HUMIDIFIER MAINS STEAM VALVE REFRIGERANT CIRCUIT CONNECTIONS DISCHARGE OR HOT GAS LINE LIQUID OR RETURN LINE NON-RETURN VALVES ON DISCHARGE AND RETURN LINES VERY LOW ETERNAL TEMPERATURE KIT SOLENOID VALVE ON THE LIQUID LINE ROUTING OF THE REFRIGERANT CIRCUIT PIPES DIAMETERS OF REFRIGERANT CIRCUIT CONNECTION PIPES REFRIGERANT CHARGING ELECTRICAL CONNECTIONS INSTALLATION OF THE REMOTE CONTROL INTERFACE INSTALLATION OF THE TEMPERATURE/HUMIDITY SENSOR SUPPLIED WITH THE UNIT INSTALLATION OF THE AMBIENT DIFFERENTIAL PRESSURE SWITCH POSITIONING OF THE AMBIENT DIFFERENTIAL PRESSURE SWITCH 26 5 CHECKS AND FIRST STARTUP 27 6 DEACTIVATION, DISASSEMBLY AND SCRAPPING 30 7 USE OF THE AIR CONDITIONING UNIT TEMPERATURE CONTROL PROPORTIONAL CONTROL PROPORTIONAL + INTEGRAL CONTROL PROPORTIONAL + INTEGRAL + DERIVATIVE CONTROL SERIES H DIRECT EPANSION AIR CONDITIONERS CHILLED WATER AIR CONDITIONER COOLING CAPACITY CONTROL WITH HOT GAS INJECTION VALVE COOLING CAPACITY CONTROL WITH HOT GAS INJECTION VALVE AND ELECTRONIC EPANSION VALVE 33 Page 3 of 60

4 7.2 HUMIDITY CONTROL SERIES H DIRECT EPANSION AIR CONDITIONERS CHILLED WATER AIR CONDITIONER SIMULTANEOUS HUMIDIFICATION AND COOLING DEHUMIDIFICATION LOCK SPECIFIC FUNCTIONS OF THE CONTROL SOFTWARE NIGHT-TIME STAND-BY UPS CONNECTION H HR HEAT RECOVERY SYSTEMS SUPPLY TEMPERATURE CONTROL (LIMIT) ANTIFREEZE SYSTEM STERILIZATION CYCLE EMERGENCY OPERATION WITH UNIT IN NEGATIVE PRESSURE 39 8 ROUTINE AND MAJOR MAINTENANCE PROGRAMMED MAINTENANCE CHART MAINTENANCE OF THE FANS REFRIGERATION CIRCUIT CHECKS MAINTENANCE OF THE ELECTRICAL BATTERY MAINTENANCE OF THE ELECTRICAL PANEL MAINTENANCE OF THE AIR FILTERS 43 9 WASHING, CLEANING AND DISINFECTION WARNINGS CLOTHING TO BE WORN DURING CLEANING OPERATIONS CLEANING SYSTEMS DISPOSAL OF USED CLEANING MATERIALS FAULT DIAGNOSIS MALFUNCTION OF THE FAN CONTROL INVERTER DIRECT EPANSION AIR CONDITIONERS REFRIGERATION CIRCUIT PROBLEMS CHILLED WATER AIR CONDITIONERS WATER CIRCUIT PROBLEMS HEATING SECTION PROBLEMS DEHUMIDIFICATION PROBLEMS VENTILATION PROBLEMS GLOSSARY NOTES 57 Page 4 of 60

5 1 HOW TO USE THIS MANUAL units. This manual describes the procedures for the installation, use and maintenance of series H air conditioning The following chapters contain information essential for obtaining the best performance from the unit you have purchased; TECNAIR LV therefore recommends that you study this manual carefully. Some of the topics covered in this manual refer to the functions of the microprocessor controls; TECNAIR LV therefore advises you to read the MICROPROCESSOR CONTROL USER MANUAL, which is also supplied with the unit, in order to gain a full understanding of the components and functions of your air conditioner. If after reading this manual you are still experiencing difficulties or require any further clarification, please do not hesitate to contact our after-sales service: After-sales office Tel / Fax : tecnairlv. it 1.1 IMPORTANT WARNINGS The equipment described in this manual has been constructed to operate without risk for the intended purposes, provided that: The installation, connection, operation and maintenance of the appliance are carried out by qualified personnel in accordance with the instructions contained in this manual. All the conditions prescribed in the user manual for the unit s microprocessor control are observed. Any other use or modification of the equipment, unless expressly authorised by the manufacturer, is deemed improper. Any injuries or damage sustained as a result of improper use shall be the sole responsibility of the user. Page 5 of 60

6 2 WARRANTY TECNAIR LV air conditioners are subject to the following warranty conditions which are automatically deemed to have been understood and accepted by the customer at the time of placing the order. TECNAIR LV guarantees that the products supplied are well made and of good quality. It undertakes during the period of warranty specified herein to repair or to replace with new at its own discretion, in the shortest time possible, those parts found to present recognised defects in materials, construction or workmanship that render them unfit for the intended use, provided that these faults are not the result of negligence on the part of the purchaser, neglect or inexperience of the user, normal wear and tear, damage caused by third parties, acts of God or other causes not arising out of manufacturing defects. TECNAIR LV however shall not be liable to for compensation for direct or indirect damage of any nature incurred for any reason. Defective components will be replaced at the Uboldo manufacturing plant, and all transportation and replacement costs shall be borne by the Purchaser. The duration of the warranty is 2 (two) years from the date of consignment. The warranty shall be rendered void automatically if the equipment is repaired or modified or in any way completed (such as, for example, in the case of non-supply of an electrical panel or similar) or in the case of the installation of non-original parts (parts not supplied by TECNAIR LV). The above warranty conditions apply provided that the Purchaser has fulfilled all contactural obligations and in particular those reagarding payment. Page 6 of 60

7 3 DESCRIPTION OF THE UNIT The machine in question is an air conditioner with direct expansion or chilled water coil for surgical rooms and medical environments. The H series is characterised by perfect air-tight sealing, TUV certified and meeting class B" requirements of EN The cabinets are made of steel sheet with all joints welded and sealed with mastic. The cabinets are painted in epoxy resin and oven cured at 150 C, after sandblasting, metalization and application of epoxy primer. The runners for battery removal and all friction points are made from AISI 304 stainless steel. The buffer panels are 25 mm thick with twins walls separated by thermal and accoustic insulation. The openable front panels are hinged and fitted with key locks. The electrical panel is equipped with an emergency safety switch. A version for outdoor installation (accessory) is also available; the outdoor version is equipped with an anticondensation heater on the electrical panel, a microprocessor control protected from sunlight by a double access panel to the electrical panel and a rain canopy. The buffer panels are of twin-wall construction with a thickness of 50 mm. The machine comprises the following sections: Electrical power and control panel Ventilation section: consisting of one or more electric Plug fans mounted to the machine frame Air treatment section: Refrigeration circuit (Series A): comprising an expansion coil with copper prepainted aluminimum cooling fins, a scroll compressor fixed to the machine frame on rubber mountings, thermostatic expansion valve, receiverdrier, plate-type condenser (accessory), low pressure switch (automatic reset) and high pressure switch (manual reset). Water circuit (Series U): with cooling expansion coil with copper pipes in prepainted aluminium cooling fins, 3-way motorised valve with manual emergency control, water circuit with anti-condensation thermal insulation Heating and post-heating water coil with cooling coil with expanded copper pipes within prepainted aluminium finning, 3-way motorised valve with emergency manual control; or electric low-thermal inertia with modulation triac Immersed electrode humidifier or modulating mains steam valve 3.1 UNIT CODE The code contains the following information: O H A 5 1 a H R407C HR O Upflow air discharge 2 H Series for surgical rooms or medical environments 3 A Cooling type: A Direct expansion coil with remote condenser U Chilled water coil with remote cooling 4 5 Nominal size (nominal cooling capacity in TONS) 5 1 Number of cooling circuits or number of rows on chilled water coil 6 a Series modification index 7 H Air flow rate/cooling capacity ratio H High air flow rate L Low air flow rate 8 R407C Refrigerant type 9 HR Air conditioner equipped with heat recovery system (if present) Page 7 of 60

8 3.2 OPERATING LIMITS SERIES H AIR CONDITIONING UNITS UNIT TYPE DIRECT EPANSION CHILLED WATER CHARACTERISTICS MAIMUM TEMPERATURE WITHOUT HEAT RECOVERY WITH HEAT RECOVERY L H +L H WITHOUT HEAT RECOVERY WITH HEAT RECOVERY 38 C 30 C 46 C 40 C 38 C 46 C MINIMUM TEMPERATURE -22 C -10 C -40 C -32 C -22 C -40 C MAIMUM HUMIDITY 95% 95% 95% 95% 100% 100% MINIMUM HUMIDITY 10% 10% 10% 10% 10% 10% STORAGE CONDITIONS Temperatures from -20 C to +50 C CONDENSERS AND DRY COOLER UNIT TYPE AIR WATER CHARACTERISTICS MAIMUM TEMPERATURE MINIMUM TEMPERATURE WITH VARIATOR WITHOUT VARIATOR Up to 30 C: T = 17 C Up to 35 C: T = 15 C Up to 40 C: T = 13 C Up to 46 C: T = 10 C WITH PRESSURE CONTROLLED VALVE 45 C WITHOUT PRESSURE CONTROLLED VALVE -25 C -40 C 7 C 25 C WATER CIRCUITS TYPE CHILLED WATER HOT WATER MAIMUM PRESSURE MINIMUM PRESSURE MAIMUM P AT VALVE MAIMUM TEMPERATURE MINIMUM TEMPERATURE INTERNAL HUMIDIFIER MAINS STEAM 16 bar (1.6 Mbar) 8.5 bar (0.85 Mbar) 8 bar (0.8 Mbar) 1 bar (0.1 Mbar) bar (0.1 Mbar) 0.2 bar (0.02 Mbar) 1 bar (100 Kpa) 1 bar (100 Kpa) C 40 C 152 C 5 C - 1 C - Page 8 of 60

9 4 INSTALLATION PROCEDURE 4.1 TRANSPORTATION Unless otherwise agreed with the Customer, TECNAIR LV shall supply their machines ex works with standard packaging consisting of a wooden pallet and protective polythene sheet. During transportation the machines must not be laid on their sides or overturned but must remain in the vertical position at all times otherwise their internal components could be damaged. As the Carrier is always responsible for damage sustained during transport by the goods, before signing the delivery note to accept the supply, check the integrity of the packaging and that there are no visible signs of damage to the conditioner or the leakage of oil or refrigerant. In the case of evident damage to the unit or if there is slightest doubt as to whether the conditioner has been damaged during transport, it is necessary to express your reservations in writing to the Carrier, whilst also informing the TECNASIR LV Sales Department. 4.2 RECEIVING THE MACHINES ON SITE For unloading of the units, please observe the procedures indicated in the illustrations reproduced below, which are also affixed to the original packaging of the unit. If the unit is not to be installed immediately after its arrival on site, it should remain in its original packaging and stored in a dry, enclosed area, preferably heated to a temperature of 15 C during the winter months. Page 9 of 60

10 4.3 POSITIONING THE UNIT AND CLEARANCES To avoid any problems and damage to the air conditioners during transportation, we recommend that the units should only be removed from their packaging when they have reached their final destination. It also essential to make sure that the floor on which the air conditioner is to be installed is capable of supporting its weight. The weight of the unit can be found in the commercial documentation or read directly from the data plate located inside the unit. During installation, respect the clearances required for routine and major servicing indicated in the drawing enclosed with the order confirmation. In general and in any case it is essential to allow a space of approximately 1000 mm along the full length of the front of the machine and 800 mm on the right-hand side; for units with rear opening, a free space of 1000 mm should be provided along the full length of the rear of the machine. Page 10 of 60

11 4.3.1 SHOCK-ABSORBING FEET Before final positioning, install the shock absorbing feet supplied with the unit (accessory). The feet are to be fixed to the underside of the unit using the bolts provided, as shown in the drawing enclosed with the order confirmation RAIN CANOPY Outdoor units are supplied with a rain canopy that is to be installed by the user. The rain canopy is to be fixed to the top of the unit, as shown in the drawing enclosed with the order confirmation. This canopy, while protecting the front of the unit from rain, does not guarantee safe servicing during inclement weather. Therefore TECNAIR LV recommends that the unit is positioned under a further canopy to provide shelter during any technical operations that may be required. Page 11 of 60

12 4.4 WATER CONNECTIONS WARNING! TECNAIR LV tests water components with dried compressed air at 24 Bar. This ensures that no water is present in the water circuits thereby preventing the possibility of freezing during storage prior to installation. However, during the positioning and installation operations, it is essential to take special care not to fill the water circuits, even accidentally, before all the necessary antifreeze measures stipulated in the design spefications have been taken (e.g. insulation, addition of glycol, etc.) CONDENSATE DRAIN AND SIPHONS All air conditioners, whether direct expansion or water chilled coils, require a condensate drain connection between the machine and the building waste drains system and the humidifier drain. The siphon, essential for draining condensate as the relative bowl is located in a point of negative pressure, is included in the supply and is to be installed when the unit the is placed in position. Page 12 of 60

13 4.4.2 WATER-COOLED CONDENSERS On machines with integral water-cooled condensers, it will be necessary to install the supply and drain lines to the condenser. The diameters of the pipes and the inlet and the outlet unions are indicated in the order confirmation. The water inlet unions on the plate-type condenser used by Tecnair are those at the bottom, while the outlet unions are at the top, as shown in the figure below. The pressure controlled valve (accessory) is essential when the water is supplied from a well, river or acqueduct; it is not essential when the water is supplied from a water tower. In practice, the valve is necessary when water during winter can enter at such low temperatures (e.g. below 15 degrees) that the machine s condensation temperature is lowered excessively. The valve is factory-installed on the condenser water inlet. If the water supply is obtained from a well or river, two filters of suitable characteristics for the type of water must be installed in parallel, (one as backup for the other) to prevent the condenser from becoming clogged by impurities in the water. To ensure that circuit pipes are installed correctly, we recommend that the following indications are observed: Use pipes made of copper or steel Support pipes with suitable brackets (1) Insulate both pipes with Armaflex type insulation (2) Install shut-off valves to facilitate maintenance (3) Install a Thermometer (4) and Pressure gauge (5) on the inlet and outlet Install a drain outlet in the lowest part of the circuit (6) Use a water/glycol solution where necessary Page 13 of 60

14 4.4.3 WATER COILS For machines with chilled water coils, as for those with hot water coils, it will be necessary to install inlet and outlet pipes. The diameters of the pipes and the inlet and the outlet unions are specified in the order confirmation. The water inlet and outlet unions are indicated in the figure below. The unions can also be identified by their adhesive labels. The maximum pressure of the water supply to the coils is 16 bar (1.6 Mpa). The maximum pressure difference between the water inlet pipe and the outlet pipe is 1 bar (100 kpa), as at pressure differences greater than this value the return spring would not be able to shut off the water flow. In the event of greater pressure differences, it will be necessary to install a pressure reducing valve upstream of the 3-way valve. To ensure that circuit pipes are installed correctly, we recommend that the following indications are observed: Use pipes made of copper or steel Support pipes with suitable brackets (1) Insulate both pipes with Armaflex type insulation (2) Install shut-off valves to facilitate maintenance (3) Install a Thermometer (4) and Pressure gauge (5) on the inlet and outlet Install a drain outlet in the lowest part of the circuit (6) Use a water/glycol solution where necessary Page 14 of 60

15 4.4.4 HEAT RECOVERY CIRCUIT TECNAIR LV does not fill the heat recovery circuit in the factory as the percentage of glycol to be added to the water will vary according to the installation site and the minimum winter temperature. It essential to use a water/glycol solution whenever there is the possibility that the outside temperature may fall below zero degrees. When filling the circuit, always add the glycol first, then the water. If the system is stably connected to the mains water supply, a shut-off cock must be installed upstream of the mains connection. A manual drain cock for the circuit is provided under the expansion vessel. Below are indicated the total capcities in litres of the air conditioner heat recovery circuits: 36 litres for model sizes 62 to 138; 48 litres for model sizes 152 to 208; 67 litres for model sizes 242 to 308; Remember that if the circuit is filled with a water/glycol solution, it must not be drained into the main sewer. Page 15 of 60

16 4.4.5 INTERNAL ELECTRODE HUMIDIFIER During installation of the unit it is necessry to connect a supply pipe (as shown in the figure) with the system characteristics indicated below. The discharge pipe is supplied ready-installed by Tenciar LV. The following conditions for correct water connection should be met: A shut-off cock must be installed in the water supply pipe There must be a mechanical filter installed on the supply line The water temperature and pressure must be within the permitted value range For more information of the characteristics of the humidifier water circuit, please refer to the User manual for the internal humidifier. Page 16 of 60

17 4.4.6 MAINS STEAM VALVE The steam distribution systems may be connected to boilers, steam heat exchangers or existing steam users. The steam supply pipe, perfectly drained, must be connected to the top of the unit, as shown in the drawing, so that there is downward gradient towards the humidifier. A shut-off damper (to be supplied by the installer) must be installed upstream of the system. We recommend using a pressure gauge. The steam supply pressure must be as stable as possible and within the range of 0.2 and 1 bar relative pressure. If the pressure exceeds this value, the installer must provide a pressure reducer to adapt the system to the steam distribution system. The steam supply and condensate drainage must be constructed from suitable materials. Joints, seals and flanges must be capable of withstanding temperatures of up to 152 C according to the supply pressure. Drainage of the steam mains pipe under pressure must be achieved efficiently. Page 17 of 60

18 4.5 REFRIGERANT CIRCUIT CONNECTIONS The pipes must be made from Gelidus type copper, soft annealed copper for pipes with diameters 26-28, and hard drawn for larger diameter pipes. To prevent copper dust or swarf from getting into the system, the pipes should be cut using a pipe cutter rather than a hacksaw. The ends of the pipes should then be carefully cleaned. If the ends are to be soldered, they should be cleaned with grade 00 glasspaper to eliminate all oxidisation and dirt. After which the pipe should be inserted in the joint and heated evenly to the melting point of the solder so that flows easily around the joint. It is important to remember that the pipes should be as short as possible with bends kept to a minimum, as the cooling capacity of the circuit can be summarised as follows: Total length of the pipes (discharge and return): > 20 m: - 2% > 40 m: - 4% > 60 m: - 6% DISCHARGE OR HOT GAS LINE This is the refrigerant line that connects the compressor outlet to the air-cooled condenser inlet. To facilitate connection inside the air conditioner, there is a section of pipe approximately 20 cmm long with one end connected to the compressor outlet and pinched and soldered shut at the other end. During operation of the air conditioner, the discharge pipe reaches a temperature of C. Thermal insulation of this pipe is not necessary as dispersion of heat along this section favours the refrigeration cycle. The pipes should only be insulated for safety reasons in cases where there is a possibility that someone could come into accidental contact with the discharge pipe LIQUID OR RETURN LINE This is the pipe that conects the condenser outlet to the air conditioner inlet valve. It is connected by soldered joints to the condenser and to the inlet valve. The operating temperature of this pipe is about 40 C; it does not need to be thermally insulated except in cases where the air conditioning system is also to operate in winter with temperatures below zero NON-RETURN VALVES ON DISCHARGE AND RETURN LINES WARNING! In installations with refrigeration circuit pipes longer than 10 metres with vertical pipe runs and the condenser located higher than the machine, it will be necessary to install a non-return valve on the refrigerant discharge pipe as near as possible to the compressor outlet. This will prevent the refrigerant, in the event of the compressor shutdown, from flowing back down the discharge pipe to the compressor and thus damaging it at the next startup and/or preventing normal operation by causing a highpressure blockage. Naturally the valve must be installed vertically and the right way round in accordance the refrigerant direction of flow. In the case of pipe sections more than 20 m long and expected minimum temperatures below 10 C it will be necessary to install another non-return valve at the outlet of the air condenser, and as close to it as possible; the valve should be installed vertically to prevent the refrigerant from flowing back to the condenser when the system is off and the external temperature is very cold, and thereby preventing efficient condensation of the refrigerant the next time the compressor is started. Page 18 of 60

19 4.5.4 VERY LOW ETERNAL TEMPERATURE KIT CEA air condensers, combined with Tecnair LV direct expansion air conditioners, are equipped as standard with air condensation pressure control via reduction of the air flow rate in accordance with the reduction in the condensation pressure. This system is very effective with external temperatures down to 20 C, thanks also to a few seconds delay before the low pressure switch trips at compressor startup. At external temperatures below this level and above all in the case of lengthy periods of non-use of the refrigeration circuit, the temperature of the liquid refrigerant can become so low that, in spite of the above-mentioned delay, the low pressure switch trips on compressor startup, thus making starting impossible. To avoid this problem, we recommend the very low temperature kit, comprised of a condenser flooding valve installed on the refriegerant connections of the air condenser. When the condensation temperature falls below +40 C, the valve progressively closes the condenser outlet, thereby flooding it and reducing proportionally the heat exchange. The refrigerant that bypasses the condenser is gaseous and at high temperature; it mixes with the liquid refigerant at very low temperature at the condenser outlet, so that the resulting temperature is such to permit the successful system startup. The volume of refrigerant present in the circuit must therefore be sufficient to be able to almost completely flood the condenser coil. During summer operation instead, the condenser coil must be almost completely free of liquid refrigerant in order to operate correctly. An oversize receiver is therefore installed in order to accommodate in summer the quantity of refrigerant that is required in winter to flood the condenser SOLENOID VALVE ON THE LIQUID LINE The scroll compressors installed on TECNAIR LV air conditioners will not be damaged by the presence of any liquid refrigerant in the crankcase. However, when the refrigeration ciruit is shutdown in the summer season, i.e. when the external temperature is just a few degrees higher than the internal temperature, the liquid refrigerant flows towards the compressor (the coldest point of the circuit) and, depending on the quantity of refrigerant in the system, floods it partially or completely. In this case, the high pressure switch may trip at the next startup. It is therefore necessary to compare the refrigerant charge in the circuit, calculated as the sum of the contents of the various components of the circuit, with the maximum quantity compatible with correct operation without the solenoid valve on the liquid pipe, as indicated in the table below. Size Compressor Rated power (Hp) Rated power (kw) Maximum quantity of refrigerant (kg) , ,6 41 3,5 11 5, ,4 71 6,5 19 5,4 81 7,5 25 7, , , ,5 Table of maximum compatible refrigerant quantities per circuit without installation of solenoid valve on liquid pipe. In the case that the calculated charge is greater than the maximum compatible quantity, it will be necessary to order the liquid pipe solenoid valve accessory which, by closing when the compressor is shut down, prevents the refrigerant flowing back towards the compressor through the liquid pipe. Obviously it is also necessary to prevent refrigerant from flowing back to the compressor through the discharge line. This is achieved by installation of the non-return valve on the discharge line. The latter valve, unlike the solenoid valve, is not offered by TECNAIR LV as an optional accessory as it must be installed when the refrigeration circuit external to the machine is installed, while the solenoid valve is installed inside the machine itself. Page 19 of 60

20 4.5.6 ROUTING OF THE REFRIGERANT CIRCUIT PIPES Correct routing of the refrigerant circuit pipes is essential to the successful operation of the air conditioner. It is necessary to take special care in the selection and positioning of the compressor discharge and suction pipes, above all when these lines are relatively long and in particular: Horizontal sections of discharge pipes between the inside and outside components must have a gradient of at least 2% in the direction of refrigerant flow. If the discharge pipe has to rise above 3 m, a siphon with the minimum radius bend possible must be installed immediately before each rising section. Additional siphons must be provided every 3 m of rising pipe. Position a counter-siphon near the condenser union. The counter-siphon must be at least as high as the highest part of the condenser coil; All pipes must be secured with brackets every 2 metres. The pipe supports should prevent transmission of vibration and at the same time allow for normal expansion and contraction of the pipes due to temperature changes during operation. A 1/4" service valve must be installed on both pipes, as near as possible to the outside unit, to allow draining and charging of the circuit. The refrigerant inlet and outlet unions on the air-cooled condenser can be identified by their adhesive labels. In any case, note that the exchange of heat between the air and the refrigerant should occur in the opposite direction to the flow. This means that the condenser inlet union for the gaseous refrigerant is the union furthest from the air inlet into the coil, i.e. the union nearest the fans. Likewise, the condenser outlet union for the liquid refrigerant is the union furthest away from the fans. Page 20 of 60

21 4.5.7 DIAMETERS OF REFRIGERANT CIRCUIT CONNECTION PIPES Use the following table to determine the recommended diameters for the discharge, liquid and suction pipes in accordance with the machine size (given by the numerical sequence in the product code). The values in the columns for pipe lengths up to 30m are also valid for longer lengths and do not need to be increased. However, it is advisable to position the air conditioners so that the pipes are kept as short as possible, to avoid significant loss of charge in the circuit and a consequent reduction in cooling capacity. Size Compressor Pipes up to 15 m long Pipes 15 to 30 m long Rated power (Hp) Rated power (kw) Discharge Liquid Suction Discharge Liquid Suction /18 10/12 26/28 20/22 14/16 26/ , /22 14/16 26/28 26/28 14/16 33/ /22 14/16 33/35 26/28 16/18 33/ /28 16/18 33/35 26/28 20/22 39/ / / / / / / , / / / / / / , / / / / / / / / / / / / / / / / / / / / / / / /42 Inside/outside diameters of refrigerant pipes REFRIGERANT CHARGING Direct expansion air conditioners are shipped without refrigerant charge. Air-cooled condensers are shipped without refrigerant charge. Machines with internal water-cooled condensers are supplied fully charged with refrigerant To charge the refrigerant circuit/s of a machine, it is necessary to consider that the total quantity of refrigerant required for a direct expansion unit equipped with remote condenser is determined by the sum of the refrigerant contents of: The air conditioner: Size Compressor Rated power (Hp) Rated power (kw) Contents of refrigerant circuit (kg) ,8 71 6,5 19 0,8 71 6,5 19 0,9 81 7,5 25 1, , ,9 Contents of pressurization refrigerant Page 21 of 60

22 Discharge pipe and liquid pipe: Weight in kg per metre of pipe (R407C) Diameters Ø 10/12 Ø 12/14 Ø 14/16 Ø 16/18 Ø 20/22 Ø 26/28 Ø 33/35 Ø 39/42 Liquid pipe 0,08 0,11 0,15 0,20 0,31 0,53 0,94 1,31 Discharge pipe 0,02 0,03 0,05 0,06 0,09 0,16 0,26 0,36 Weight of refrigerant in pipes Air-cooled condensers with CEA axial fans: Model Contents of refrigerant circuit (kg) Model Contents of refrigerant circuit (kg) CEA 21c H/V 0,66 CEA 91c H/V 3,8 CEA 21c/LN H/V 1,0 CEA 101c H/V 5,2 CEA 31c H/V 1,32 CEA 101c/LN H/V 4,0 CEA 31c/LN H/V 2,0 CEA 111c H/V 5,3 CEA 41c H/V 1,32 CEA 111c/LN H/V 6,0 CEA 41c/LN H/V 1,9 CEA 121c H/V 4,0 CEA 51c H/V 1,95 CEA 121c/LN H/V 7,3 CEA 51c/LN H/V 2,9 CEA 131c H/V 4,0 CEA 61c H/V 2,58 CEA 131c/LN H/V 8,0 CEA 71c H/V 1,89 CEA 151c H/V 6,0 CEA 71c/LN H/V 3,6 CEA 181c H/V 8,0 CEA 81c H/V 2,88 CEA 181c/LN H/V 8,0 CEA 81c/LN H/V 4,0 CEA 201c H/V 10,5 Refrigerant contents of the circuit The sum of the refrigerant contents (air conditioner + liqid pipe + discharge pipe + condenser) gives the total refrigerant charge required by the system: Refrigerant contents of air conditioner OHA 51H: 0,8 Refrigerant contents of condenser CEA 61: 2,6 10 metres of 16/18 diameter discharge pipe = 0.06 kg/m x 10 = 0,6 10 metres of 10/12 diameter liquid pipe = 0.08 kg/m x 10 = 0,8 Total refrigerant content: 4,8 Obviously machines with two refrigerant circuits (e.g. models 202), the charge for each circuit is to be calculated in the same way as model 101 machines. It is also necessary to add oil to the circuit in a quantity equal to approximately 5% of the total amount of refrigerant in the circuit. We recommend the use of SUNISO 3 GS for machines charged with R22 and MOBIL EAL ARTIC 22 BC or equivalent polyesters for machines charged with R407C. Page 22 of 60

23 4.6 ELECTRICAL CONNECTIONS WARNING! BEFORE CARRYING OUT ANY OPERATIONS ON THE UNIT, SET THE MAIN SWITCH TO POSITION O The external electrical connections of the air conditioner must satisfy the following preseciptions: They must be suitably dimensioned to withstand the maximum load in Amperes indicated on the electrical wiring diagram and on the data plate located inside the electrical compartment of the unit itself. The power supply must be within the following limits in order to avoid possible malfunction of the installed components: o Voltage tolerance limits: ± 10% o Frequency tolerance limits: ± 2% The power supply line from the external RCBO (Residual Current Breaker with Overcurrent protection) to the machine must be direct without any interruptions or junctions. The thermal-magnetic circuit breaker, the installation of which is responsibility of the Customer, is essential in order to provide overcurrent protection on the supply line (Articles and of standard CEI EN ), and must be located as near as possible to the machine. The thermal magnetic circuit breaker must be equipped with a residual current device (RCD) with a trip settings of ma to provide protection for persons against both indirect and direct contact, in addition to thermal and magnetic overload protection. The RCD serves also to protect the air conditioner against insulation failure. The earth connection must be made with a conductor having the minimum cross-section indicated in the wiring diagram. To prevent operating problems with the microprocessor controls, it is necessary that no other loads (pumps, condensers, etc.), even those that are part of the same system, are connected downstream of the main switch of the air conditioner, unless explicit permission is granted by TECNAIR LV. If this condition cannot be met, it will be necessary to connect suppressors (R + C) in parallel with the coils of the relays of any such loads. The signal/control cables must be kept separate from high-current cables, power cables and any cables that are potential sources of electromagnetic interference. To avoid possible damage to electrical and electronic equipment, particularly in outdoor units, caused by voltage surges in the electrical supply line, TECNAIR LV recommends evaluating the necessity of installing SPDs (Surge Protection Device) appropriately rated for the type of installation and the frequency of direct lightning strikes on the electrical supply line. Page 23 of 60

24 4.6.1 INSTALLATION OF THE REMOTE CONTROL INTERFACE If the complete terminal or reduced version is to be panel or recess mounted, the maximum thickness of the panel must be 6 mm; if the terminal is to recessed mounted in a wall, a masonry box with internal dimensions sufficient to accommodate the terminal and the connection cables must be provided. The drilling templates are illustrated below: Complete terminal Reduced terminal The user terminal is to be conected to the main board via a 6-wire telephone cable. To make the connection, it is sufficient to plug one of the telephone connectors into one of the terminals of the TCON6 board and the other into the terminal connector, as shown in the wiring diagram. For safe connection, use the toroid supplied with the user terminal to avoid interference on the line could damage the memory or components of the board itself. If the terminal is disconnected from the board when the unit is powered on, we recommend waiting at least 5 seconds before reconnecting it. --{}-{}- Connection of user terminals Page 24 of 60

25 4.6.2 INSTALLATION OF THE TEMPERATURE/HUMIDITY SENSOR SUPPLIED WITH THE UNIT There are two types of sensor supplied with the unit (accessories): 1) Temperature sensor or temperature/humidity sensor for duct installation: Temperature sensor for the supply air duct: To be installed inside the supply air duct at the point nearest to the outlet vents. The humidity sensor is to be installed on board the machine in the return air compartment. Temperature and humidity sensor for the retun air duct To be installed inside the return air duct at the point nearest to the return air inlet vents. 2) Wall-mounted temperature sensor or temperature/humidity sensor: To be installed in the room to be controlled at a height of approximately 1.7 m. Take care during sterilization to protect the sensor to prevent damage to the electronic components! INSTALLATION OF THE AMBIENT DIFFERENTIAL PRESSURE SWITCH The differential pressure switch installed in the room to be controlled is of fundamental importance in that it continuously transmits the ambient pressure reading to the microprocessor control. It therefore enables the microprocessor control to take the actions necessary to maintain the correct positive or negative pressure in the room. The pressure switch uses two aeraulic inputs and an electrical terminal block to be connected with a shielded 3x0.35 cable (AWG22) to the terminal block of the electrical panel, as shown in the wiring diagram. The connection cable is not supplied by TECNAIR LV. The difference in pressure between the controlled room and the reference environment is measured via two flexible transparent pipes with diameter 4/7. Page 25 of 60

26 4.6.4 POSITIONING OF THE AMBIENT DIFFERENTIAL PRESSURE SWITCH The pressure switch can be positioned in various ways. The following figures show the typical types of installation. Wherever you decide to install the pressure switch, the following points are essential Connect the pipe with the free end in the room to the positive socket of the differential pressue switch, even in the case of negative room pressure, protruding a few centimetres from the wall or ceiling. Ensure the pressure switch is at least 2 metrs from the floor level, so that it is better protected against dust deposits or possible impact. Installing the differential pressue switch in the room Installing the differential pressure switch in an environment adjacent to the room Installing the differential pressure switch in the room Page 26 of 60

27 5 CHECKS AND FIRST STARTUP WARNING! BEFORE CARRYING OUT ANY OPERATIONS ON THE UNIT, SET THE MAIN SWITCH TO POSITION O Before the Mnufacturer s personnel proceed with the testing and startup of the machines, the checks listed in the following form must be carried out. DATE PLACE OPERATOR S SIGNATURE CUSTOMER S SIGNATURE Checks to be carried out before calling technician for startup Machine startup with the refrigeration circuit requires that the units are powered on for at least two hours prior to the arrival of the technician in order to allow the compressor s crankcase oil heater to reach working temperature and allow evaporation of any refrigerant deposited in the compressor to ensure that the compressor/s function/s correctly. The crankcase heaters switch on automatically when the machine is powered on. REFRIGERANT CIRCUIT CHECKS DESCRIPTION POSITIVE NEGATIVE Check discharge pipe diameter conforms with indication in the installation manual. Check horizontal sections of the discharge line have a gradient of at least 1% in direction of refrigerant flow Check that siphons are installed at the lowest point of each rising pipe and every 3 m along rising pipe sections, as well as a counter siphon at the highest point of the rising pipe. Check the non-return valve is installed as near as possible to the compressor with the apertue in the direction of refrigerant flow (pipes longer than 5 m). Check the non-return valve is installed as near as possible to the compressor with the aperture in the direction of refrigerant flow (pipes longer than 10 m). Check that the discharge pipe is insulated in the sections where accidental operator contact is possible (pipe operating temperature approx. 70/80 C) Check that support brackets are installed on the discharge pipe every 3 m and are not too tight so as to allow expansion of the pipe. Page 27 of 60

28 8 Check that the diameter of the liquid pipe conforms to requirements. 9 Check that support brackets are installed every 3 m. 10 Check that refrigerant circuit valves are open, including the valve on the hot gas injection pipe. 11 Check the electrical connections to the condenser disconnect switch Check that the disconnect switch is in the closed position (condenser powered on). Check the refrigerant pipe connections between the condenser and the evaporator are in the opposite direction to the air flow and the refrigerant flow. Check that the condenser is correctly popsitioned far away from walls and/or other condensers to avoid recirculating air currents that could impair its operation. 15 Check the charge level in the refrigerant circuit. 16 Check the evaporation pressure. 17 Check the condensation pressure. 18 Check the superheating of the refrigerant aspirated by the compressor. 19 Check the subcooling of liquid refrigerant. 20 Check that the liquid line filter is not clogged. 21 Check the power consumption of the compressor. 22 Check operation of the high pressure control switch. 23 Check operation of the low pressure control switch. 24 Check the compressor operating temperature. WATER CIRCUIT CHECKS DESCRIPTION POSITIVE NEGATIVE Check that the inlet and outlet of the hot and cold water supplies conform with the arrows marked on the fittings or, if these are missing, with the drawings in the installation manual of the machine. Check that all the liquid supply pipes are provided with manual shut-off cocks just outside to the machine, and that theses cocks are open. 27 Check that the condensate drain outlet does not have taps or restrictions Check that the hardness of the water supply is between 10 and 40 French degrees. Check that the humidifier supply fitting is connected to the mains drinking water supply and that it is provided with a manual shut-off valve just outside the machine. Page 28 of 60

29 ELECTRICAL POWER SUPPLY CHECKS DESCRIPTION POSITIVE NEGATIVE 30 Check the connetion of the three phases, neutral and earth. 31 Check that the power supply voltage and frequency are within the tolerance limits of +/- 10%. CHECKS FOR AMBIENT SENSOR AND REMOTE TERMINAL CONNECTIONS (IF PRESENT) DESCRIPTION POSITIVE NEGATIVE 32 Check positioning as prescribed in the installation manual Check that electrical connection between the sensors and the electrical panel is as indicated in the wiring diagram and the installation manual. Check the installation and connection of the ambient pressure switch is as indicated in the wiring diagram and installation manual. NOTES ON ANOMALIES ENCOUNTERED DURING CHECKS.... Page 29 of 60

30 6 DEACTIVATION, DISASSEMBLY AND SCRAPPING WARNING! BEFORE CARRYING OUT ANY OPERATIONS ON THE UNIT, SET THE MAIN SWITCH TO POSITION O TECNAIR LV air conditioners must only be dismantled by specialised technical personnel. In any case, the following points must be observed: Switch off the air conditioner first by way of the microprocessor control Open the machine s main door lock switch Open the external thermal-magnetic circuit breaker to isolate the air conditioner from the electrical power supply The refrigerant contained in the air conditioner should be disposed of in accordance with the waste disposal and safety regulations applicable in the country of installation. Disconnect, where applicable, the refrigerant lines, the water connections and the condensate drain lines from the air conditioner. The scrapping of air conditioner is subject to the prevailing legal requirements in the country of installation. TECNAIR LV recommends that you contact an authorised waste disposal contractor for this purpose. Air conditioners are made primarily from raw materials such as aluminium, copper and steel. Page 30 of 60

31 7 USE OF THE AIR CONDITIONING UNIT 7.1 TEMPERATURE CONTROL The heating and cooling devices are controlled in accordance with the temperature readings measured by the ambient sensor (or return air sensor) This temperature reading is compared with the set-point temperature, and the heating and cooling devices are activated according to the difference between these temperature values. The proportional band determines the operating range of the air conditioner and may assume different values during heating and cooling. The dead band identifies a range around set-point in which no control action takes place. The following diagrams illustrate the behaviour of the heating and cooling devices. The percentage values indicate the degree to which the modulating valves are opened PROPORTIONAL CONTROL Acts on the response speed of the system; increasing this value decreases operating error to one step, but makes the system less stable (leads to over-sensitivity of the control system); The control action is a function of the difference between the desired temperature or humidity value (set-point) and the value actually measured expressed as a percentage of the proportional band PROPORTIONAL + INTEGRAL CONTROL The control action is a function of the percentage difference on the poportional band between the desired temperature and the calculated average temperature in the integration time. In this way the control operates on the basis of an historical archive of the values assumed by the temperature during the integration time and not just on the basis of the instantaneous temperature value. This eliminates the effect of any sudden and temporary changes in the temperature PROPORTIONAL + INTEGRAL + DERIVATIVE CONTROL Increases system damping and stability, thus enhances the other two control actions (with their respective benefits) while maintaining stability. The control action is effected in accordance with the function: 1 de Output = Kp * ( e + * e dt + Td ) Ti dt where Kp represents the proprotional band, e represents the error (Input - Setpoint), i.e. the difference between the actual value and the set-point value, Ti and Td are respectively the derivation and integration times, from the time interval taken into consideration and the error interval. We advise that initially only Proportional Control is used, adjusting the Kp value until satisfactory operation is obtained; at this point integral control action Ti may be introduced, while simulatenously reducing the Kp so as not to impair system stability. Finally, on introducing derivative control action Td, the system tends to stabilise and it will therefore be possible to increase the Kp again. Page 31 of 60

32 7.1.4 SERIES H DIRECT EPANSION AIR CONDITIONERS AIR CONDITIONER WITH A SINGLE COMPRESSOR AIR CONDITIONER WITH TWO COMPRESSORS CHILLED WATER AIR CONDITIONER COOLING CAPACITY CONTROL WITH HOT GAS INJECTION VALVE Control of cooling capacity is achieved through an electronic hot gas injection system. Injection of hot gas downstream of the thermostatic valve reduces cooling capacity in proportion to the request from the control system. With this system it is possible to modulate the cooling cpacity between 50% and 100% of the rated capacity, and obtain a corresponding reduction in power consumption. The opening of the injection valve is controlled by a 0 to 10V signal directly proportional to the percentage difference of the temperature from the set-point in relation to the proportional band. Page 32 of 60

33 7.1.7 COOLING CAPACITY CONTROL WITH HOT GAS INJECTION VALVE AND ELECTRONIC EPANSION VALVE In cases where a 50% reduction in cooling capacity is not compatible with the requirement for perfect system control, installation of an electronic expansion valve in place of the standard thermostatic expansion valve allows electronic control of the hot gas to reduce cooling cacpity down to just 10% of the system s rated capacity. The electronic expansion valve (EEV) allows control of superheating on the suction line for more efficient and versatile operation of the refrigeration system. Efficient, because the optimisation and stabilization of the flow of refrigerant to the evaporator increases the overall output of the system while at the same time guaranteeing safety (less frequent tripping of the low pressure control switch, less liquid refrigerant returning to the compressor,...). Furthermore, if the EEV is correctly dimensioned, the use of the floating condensation (and evaporation) pressure or at low set-point significantly increases system efficiency, ensuring reduced power consumption and greater cooling output. Versatile, because the EEV affords the possibility to serve refrigeration units of different cooling capacities in widely differing operating conditions. The following diagram shows a typical system layout. The priorities to be considered for optimal control of the refrigeration system are a high and constant cooling capacity as well as an equally low and stable superheating. Page 33 of 60

34 7.2 HUMIDITY CONTROL Humidification control action is effected proportionally through the use of the following components: Integrated immersed electrode humidifier External humidifier (not supplied by TECNAIR LV) Proportional control provides a modulating effect on the quantity of steam produced, which in the case of the integrated humidifier ranges from to 8 to 100% of the total production, for both types of microprocessor control. Dehumidification control is effected by a startup/opening step of the cold component with activation at the limit of the proportional control band. Once the component has been activated, the control proceeds by regulating the cooling capacity, in the case of the hot gas bypass or water chilled coil, up to the set-point. The cooling capacity is never reduced below 60% of the total to allow the effect of dehumidification. The figure illustrates the system described above: SERIES H DIRECT EPANSION AIR CONDITIONERS AIR CONDITIONER WITH A SINGLE COMPRESSOR AIR CONDITIONER WITH TWO COMPRESSORS Page 34 of 60

35 7.2.2 CHILLED WATER AIR CONDITIONER SIMULTANEOUS HUMIDIFICATION AND COOLING Cooling the air increases its relative humidity until it reaches saturation point. It is clear that the air s capacity to absorb vapour depends on its relative humidity and falls to zero near saturation point. Attempting to humidify air in these conditions, i.e. immediately after cooling, cause the vapour to condense and the consequent formation of puddles of water inside the machine, and significant energy wastage. For this reason, series H units are equipped with devices to interrupt humdification during operation: Compressurized units: humidification is disabled by the specific parameter. Chilled water unit: humidification is enabled by the specific parameter. Should it be necessary to humidify the air at the same time as cooling it, we recommend installing an external room humidifier DEHUMIDIFICATION LOCK In cases where a post-heating coil (accessory) is not installed, problems of low temperature supply air may occur during dehumidification. In this case, a software lock intervenes to prevent a significant drop in room temperature. If the air conditioner is dehumidifying and the temperature exceeds 150% of the proportional band, the microprocessor will inhibit dehumidification, thereby giving priority to temperature control. Dehumidification may restart, if still required, when the temperature reaches 50% of the proportional band. Page 35 of 60

36 7.3 SPECIFIC FUNCTIONS OF THE CONTROL SOFTWARE This chapter describes certain specific functions of the control software for the series H unit. For more detailed descriptions of the components and accessories involved in the processes, pleae refer to the installation manual supplied with the unit NIGHT-TIME STAND-BY This function, which is activated from the specific screen page, enables the unit to operate at reduced level during the hours in which the room is not in use, thereby allowing energy savings. Stand-by can be activated by daily time bands, by setting start and end times, by digital input and by remote supervisor. unit. In the event of an emergency, the stand-by can be deactivated at any time to restore normal operation of the During night-time stand-by, the unit is controlled using the folowing parameters: TEMPERATURE CONTROL Effected through two set-points, one high and one low, that afford a wide window of inactivity while maintaining the room conditions within the minimum and maximum values. HUMIDITY CONTROL Effected in the same way as temperature control. AIR FLOW RATE AND AMBIENT PRESSURE CONTROL Both are reduced to the minimum values that can be set. PRESSURE CONTROL IN SUPPLY AND RETURN AIR DUCTS Controlled in the same way as air flow rate TEMPERATURE/HUMIDITY ALARM CONTROL Effected through thresholds linked to the various setpoints described above UPS CONNECTION If the unit is connected to a UPS system via the specific digital input (see wiring diagram), it will be possible to reduce the electrical power consumption of the unit to the minimum while still guaranteeing the sterility of the air in the room. During operation powered by a UPS, components with high power consumption will be disabled. COMPRESSORS IMMERSED ELECTRODE HUMIDIFIER ELECTRICAL HEATING AND POST-HEATING COILS All components not included in this list will continue to function normally. Page 36 of 60

37 7.3.3 H HR HEAT RECOVERY SYSTEMS The heat recovery system is based on the exchange of heat between external air and the air returned from the conditioned room. The transfer of heat between the two coils (shown in figure within the red circle) occurs via a specific pump and an expansion valve that uses water as the heat exchange medium. The system either adds or removes heat to/from the air entering the machine, in accordance with the preset temperature regime. The operation of the heat recovery system depends on the temperature values: T ext = external air temperature T rip = return air temperature SUMMER OPERATION: If the condition T ext - T rip > T is met, where T is a parameter that can be set via sotware configuration between 1 C and 5 C, and the water pump is in operation, the externa; air entering the machine is cooled free of charge. WINTER OPERATION: If the condition T ext - T rip < T is met and the water pump is in operation, the external air entering the machine is heated free of charge. Page 37 of 60

38 7.3.4 SUPPLY TEMPERATURE CONTROL (LIMIT) The control of high and low supply temeparure is effected by way of various types of control in accordance with system requirements. High temperature can be controlled in the following ways: ALARM ONLY: after the time delay, an alarm is generated STOP HOT: when the alarm threshold is exceeded, the hot component is deactivated; if, after the time delay, the temperature has still not fallen below the threshold, an alarm is generated. HOT + COLD: when the alarm threshold is exceeded, the cold component is activated proportionally to maintain the temperature below the alarm theshold. If after the time delay the temperature has still not fallen below the threshold, an alarm is generated. Low temperature can be controlled in the following ways: ALARM ONLY: after the time delay, an alarm is generated COLD STOP: when the alarm threshold is exceeded, the cold component is deactivated; if, after the time delay, the temperature has still not risen above the threshold, an alarm is generated. HOT + COLD: when the temperature exceeds the alarm threshold, the cold component is activated proportionally to maintain the temperature below the alarm theshold. If after the time delay the temperature has still not fallen below the threshold, an alarm is generated. HOT + COLD: when the temperature exceeds the alarm threshold, the hot component is activated proportionally to maintain the temperature above the alarm theshold. If after the time delay the temperature has still not risen above the threshold, an alarm is generated ANTIFREEZE SYSTEM This system, enabled only when the relative temperature sensor and heating coil are installed, affords active protection against freezing and can be operated with two different management strategies: DAYTIME: if the antifreeze sensor, during normal operation, detects a temperature below the programmable setpoint, the system activates the heating: If after reaching 1000% the temperature is still below the alarm threshold, the fans will be switched off and a message will appear on the main screen page. The moment the temperature rises above the programmed threshold, the fans will be switched on again. If the problem recurs more than 3 times in one hour or if the temperature remains below the alarm threshold with the fans off for more than 10 minutes, a major alarm message will be displayed and the unit will be shut down. NIGHT-TIME: if the unit is tunred OFF at night, an additional protection system acts as above, opening the hot valve so that the water circulates in the coil and thus prevent freezing. THIS SYSTEM CAN ONLY ACTIVATED ON UNITS WITH CHILLED WATER COILS! Page 38 of 60

39 7.3.6 STERILIZATION CYCLE This function, which can be activated from the relative menu, serves to disinfect the room, the air ducts and the unit itself through the introduction of a sterilizing gas such as Glutaraldeide. The operating cycle is comprised of three stages: 1) DISTRIBUTION OF THE STERILIZING AGENT: the unit stops the exhaust fan, closing the relative damper, and fully opens the recirculation damper. In this way the sterilizing agent reaches and saturates all components of the aeraulic circuit. (Default 1 hour) 2) UNIT SHUTDOWN: in this stage the unit is shut down completely so as to allow the sterilizing agent to work. (Default 1 hour) 3) WASHING: the unit activates both fans at 100% and shuts completely the recirculation damper. This introduces large quantities of clean air expels all traces of the sterlizing agent. (Default 1 hour) 4) CYCLE END: the sterilization cycle is terminated and the unit resumes normal operation. THE CYCLE CAN ONLY BE ACTIVATED IF THE RECIRCULATION DAMPER IS INSTALLED EMERGENCY OPERATION WITH UNIT IN NEGATIVE PRESSURE This emergency procedure can be activated by holding pressed the red EMERGENCY button. During the emergency period, the unit will work with a negative ambient pressure set-point so as to ensure that potential contaminants are not released into the controlled environment. The set-point, which is set automatically by the software and cannot be modified, is -15 Pa. Once the emergency period is over, normal operating conditions can be restored by holding pressed the blue NORMAL key. NOTE: The state of emergency will be activated only in the case of operation with positive ambient pressure control (OVER-PRESSURE). The negative pressure value obtainable will depend on the controlled environment. Page 39 of 60

40 8 ROUTINE AND MAJOR MAINTENANCE WARNING! BEFORE CARRYING OUT ANY OPERATIONS ON THE UNIT, SET THE MAIN SWITCH TO POSITION O 8.1 PROGRAMMED MAINTENANCE CHART The recommended unit maintenance programme is summarised in the following chart: CHECK EVERY COMPONENTS 1 MONTH 3 MONTHS 6 MONTHS 1 YEAR Check general condition: corrosion, mountings, cleanliness Check motor noise FANS Check the rotor: vibration, imbalance Check power consumption Clean the rotor and the motor AIR FILTERS Check the condition of the filters: Mountings, signs of damage Check filters are not clogged Check operation and calibration of differential pressure switches Check the system operates correctly Check the display LEDs and the alarm status MICROPROCESSOR CONTROL Check the mother board connections Check the control and display boards Check that the unit s sensor readings are correct Check the condition of the cylinder Carry out the automatic cylinder washing pocedure INTERNAL HUMIDIFIER Check the condition of the filling and drain valves Carry out manual washing with limescale preventer Inspect the gaskets/seals Renew if necessary Page 40 of 60

41 MAINS STEAM VALVE Check the condition of the valve Check that the valve opens and closes correctly Check the condensate drain Check the operating pressures Check operation of the maximum humidistat ELECTRICAL PANEL Check the unit is receiving power correctly Check the electrical connections Check the power consumptions of electrical components Test safety devices Renew protection fuses Check circuits for leaks Bleed air from circuits WATER CIRCUITS Check circuit temperatures and pressures Check operation of the 3-way valve Check the quantity of glycol in the circuit Check the water circulates correctly Check the operating temperatures and pressures Check the condition of the compressor Check the condition of the liquid sightglass filter REFRIGERANT CIRCUITS Check operation of the safety devices Check the calibration and operation of the control valves Check the refrigerant charge level and for circuit leaks Check the lubricating oil level Check the condition of the remote condenser Check the calibration of the remote condenser regulator CONDENSERS Check that the remote condenser is receiving power correctly Check the pressure contolled valve of the water cooled condenser Check the condenser water circulates correctly Page 41 of 60

42 8.2 MAINTENANCE OF THE FANS Fan maintenance operations must be carried out in conditions of maximum safety and always with the unit switched off. During maintenance, check the following: Periodically check that the fan blades are clean and remove all dirt and encrusted deposits that could affect the balance of the rotor and thus damage the bearings. Check that the cooling fins of the fan motors are clean. If the fans produce any unusual noises during operation, switch off the machine and identifty and rectify the problem, renewing the fan or the motor if necessary. 8.3 REFRIGERATION CIRCUIT CHECKS The refrigeration circuit does not require maintenance other than the periodic checks indicated the chapter Start up. The first of these checks is to look for leaks, as indicated by the the presence of small bubbbles visible in the liquid viewed through the sight glass. The cooling coil must be inspected and, if necessary, cleaned with hot soapy water using a brush with long soft bristles. Compressed air may also be used providing that it is free of oil. 8.4 MAINTENANCE OF THE ELECTRICAL BATTERY It is sufficient to check that the battery is clean and that the power consumption in Amps is as specified in the technical data sheet. If the machine is equipped with a modulating electrical batttery, it is advisable to also check occasionally that the modulator is functioning correctly. To do this, it is sufficient to check that the machine behaves correctly during heating operation, with the relative screen page showing a voltage of 0-10 V for the microprocessor output to the modulator. (See User manual). 8.5 MAINTENANCE OF THE ELECTRICAL PANEL Maintenance of the electrical panel must be carried out every two months as follows: Electrical and electronic components: Clean using a compressed air jet at a minimum distance of 30 cm (to avoid danging plastic parts), pay particular attention to cooling fans and heat sinks. Air inlets: The air inlets are equipped with filters that afford protection to IP54. These filter must be cleaned or, if this is not possible, renewed. WARNING! Failure to clean and/or renew the air inlet filters will result in loss of IP54 protection. TECNAIR LV shall not be liable for any damage resulting from a lack of correct maintenance of these filters. Page 42 of 60

43 8.6 MAINTENANCE OF THE AIR FILTERS On TECNAIR LV air conditioners, all air filters are equipped with differential pressure switches to monitor pressure loss caused by clogging. The microprocessor signals when the measured pressure difference exceeds the set value. To change the trip setting of a differential pressure switch, simply unscrew the cover and turn the setting dial to the desired pressure differential value. FILTER TYPE POSITION VALUE [Pa] F5 filter Air return 250 F6 filter External air 300 F9 filter Supply air 400 The filters must be renewed every time the relative clogged filter alarm is generated. To change a filter, switch off the unit, open the front panels and remove the filter. The panels to be opened are exclusively those indicated in the drawing supplied with the machine. They are to be opened using the key provided. WARNING! Used filters are to be disposed of as SPECIAL WASTE. Under no circumstances may the air conditioners be operated without the filters. To ensure the efficiency of the filters, it is necessary to install the 15x3 mm seal. We also recommend installation of an external air pre-filtration system with an efficiency of at least G3 to avoid frequent clogging of the F6 filters and thus reduce the system operating costs. Page 43 of 60

44 9 WASHING, CLEANING AND DISINFECTION WARNING! BEFORE CARRYING OUT ANY OPERATIONS ON THE UNIT, SET THE MAIN SWITCH TO POSITION O 9.1 WARNINGS 1) Before proceeding with any cleaning operations, it is essential to read the following information and make sure that you have fully understood it. 2) All cleaning operations must be carried out in accordance with the instructions given here below, as incorrect procedures could be seriously damage the equipment and/or be hazardous for the operator. 3) TECNAIR LV air conditioners contain rotating parts, live parts and pressurised parts. To avoid all risks, before opening the unit for any cleaning operations, it is essential to proceed as follows: Make sure that the unit has been switched off. Make sure that all moving parts (compressor in the drive compartment, exhaust fan and supply fan) are stationary (i.e. have have stopped rotating). Make sure all electrical power supply lines to the appliance are disconnected. 4) The following instructions apply exclusively to the cleaning of the air conditioner. It is assumed that the maintenance, cleaning and/or disinfection of system components (inside the air ducts, air vents and/or diffusers, germicidal lamps, humidifier water supply treatment systems, condensate drainage systems, ect.) are carried out at the intervals and in the manner indicated by the respective manufacturers and by the system installer. 5) The cleaning, washing and disinfection of the air conditioner alone, even when carried out in accordance with the instructions given in this manual, are not in themselves sufficient to ensure the necessary aseptic conditions in the entire system TECNAIR LV series H air conditioners, although equipped with internal filters, are designed for climate control, not to ensure the sterility of the environment. To guarantee the necessary degree of environmental sterility, the installer must install under their own responsibility and at their own expense absolute filters at each air vent or diffuser in the room. 6) The cleaning of the series H air conditioners used for the climate control of operating theatres must be carried out by specially trained personnel of the hospital maintenance department to prevent bacterial contamination of the air conditioners. Only in this way is it possible to safeguard the helath of all cleaning operatives, medical personnel and patients who enter the rooms in which the air conditoners are operated. 9.2 CLOTHING TO BE WORN DURING CLEANING OPERATIONS Unless otherwise indicated by the doctor in charge of the surgical room, all cleaning personnel, in order to safeguard their own health as well as ensure successful result of the operations undertaken, must wear: Clean overalls Eye protection Latex rubber gloves (during cleaning and disinfection of the operating compartments, gloves must be changed as soon as they become dirty). Antiseptic mask Shoe covers On completion of the cleaning operations, all the protective clothing worn must be disposed of as infected waste, except the overalls which may be used after washing and disinfection. Page 44 of 60

45 9.3 CLEANING SYSTEMS As the air conditioners contain electrical components (electric motors, terminal blocks, sensors, etc.) that could be damaged by high pressure water jets or high temperatures, and a refriegeration system that must not be subjcted to high pressures, the use of steam or pressurised water jets for cleaning operations is strictly prohibited. The water and disinfectant solution used to disinfect the appliance must only be used in the from of a nebulised spray. Use a manually operated sprayer to obtain a nebulised spray for air conditioner cleaning. For washing and disinfection operations, use exclusively a 4% ammonium chloride and water solution (or a chemically equivalent commercial solution) applied using a manual sprayer. Every air conditioner can be divided into three zones: 1) TECHNICAL COMPARTMENT: the part of the air conditioner containing the control systems and the compressors. In this zone there is no air circulation and therefore disinfection is not normally required. The technical compartment must be cleaned using a vacuum cleaner, with a renewable paper filter and a soft brush installed on the suction nozzle. Unless otherwise indicated by the doctor in charge of the room, used vacuum cleaner filters do not necessarily have to be disposed of as contaminated waste. 2) OPERATING COMPARTMENTS: the zone of the air conditioner containing parts where air treatment takes place. This zone is subject to a flow of external air to the operating room after suitable treatment, and to the flow of air returning from the operating room and expelled into the environment. Notwithstanding the filtration systems present in the air suction, retunn and distribution system and in the air conditioner itself, this zone may harbour bacteria which could proliferate when the unit is idle and thus create a health hazard when the unit is next used. These compartments must be washed and disinfected at least once a month or each time a surgical operation is performed that carries a risk of spreading harmful bacteria. However, as the frequency and manner in which operating rooms are used can vary greatly, the responsibility for deciding when washing and disinfection of these compartments is necessary rests exclusively with the person in charge of the medical department. Proceed as follows: Remove the air filters before proceeding Remove the pre-heating water coil (if present) as otherwise it could limit the effectivenss of any cleaning of the cold coil. Wash the cold coil with sterilizing solution spray. After re-installing the pre-heating coil, wash it usimg the same method. Wash the heat recovery coils (if present). Wash thoroughly the walls of the operating compartments, including those housing the fans. Allow the unit to dry before refitting the filters. 3) ETERIOR OF THE AIR CONDITIONER: the exterior of the unit is made from enamelled sheet steel and should only be cleaned in accordance with the criteria and the procedures specifically indicated in this manual. If the air conditioner is installed inside the operating theatre or in a communicating room (anaesthetic room, wake-up room, post-operative observation room, etc.), its exterior must be cleaned and disinfected at the same time as its operating compartments, unless otherwise indicated by the ward manager. If instead the unit is installed in a technical room not in communication with the operating theatre, it is sufficient to clean the exterior when traces of dust or grease are apparent 9.4 DISPOSAL OF USED CLEANING MATERIALS The cleaning of the air conditioners produces both solid (old filters, operator s clothing, worn drivebelts, etc.) and liquid waste materials (washing fluid residue and water used for rinsing). The solid waste materials should be put into sealed containers and disposed of along with the contaminated hospital waste. Liquid waste can be allowed to flow out through the drain outlets of machine s condensate collection trays These trays are to be connected to the hospital's waste disposal system for hazardous liquid waste Page 45 of 60

46 10 FAULT DIAGNOSIS WARNING! BEFORE CARRYING OUT ANY OPERATIONS ON THE UNIT, SET THE MAIN SWITCH TO POSITION O This chapter contains information to assist the operator in tracing any faults that may arise with the machine Starting from a description of the nature of the problem, we provide indications on the probable causes and possible remedies. The description of the causes is generic and therefore takes into consideration the most complete versions of the machine; it is the task of the operator to determine which of the information provided applies to the machine in question. All servicing and repair of the machine must be carried out by qualified personnel only. We strongly recommend that you do not attempt any operations on the machine unless you have a good understanding of its operating principles. Key to the fault diagnosis diagram: Page 46 of 60

47 10.1 MALFUNCTION OF THE FAN CONTROL INVERTER. The following table lists the fault codes, the causes and the remedies for problems regarding fan control inverters. CODE FAULT POSSIBLE CAUSE REMEDY 1 Overcurrent 2 Over-voltage 3 Earth fault 8 System fault 9 Under-voltage Ouput phase supervision Inverter undertemperature Inverter overtemperature The inverter has detected that the current at the outlet terminals is too high (>4*IH) Sudden increase in load Short-circuit in motor wiring Unsuitable motor The voltage of the intermediate DC circuit has exceeded the preset limits. Acceleration time too short High voltage surges in the supply line Current measurement has determined that sum of the motor phase currents is not zero. Faulty insulation of the wiring or the motor. Component fault Malfunction The voltage of the intermediate DC circuit is below the preset voltage limits. Most probable cause: supply voltage too low. Internal inverter fault. Current measurement has determined that there is no current on one of the motor phases. The temperature of the heat sink is below 10 C. The temperature of the heat sink is greater than 90 C. The over-temperature alarm trips when the heat sink temperature rises above 85 C. Check the load Check the size of the motor Check the wiring Increase the deceleration time. 15 Motor stalled The motor stall protection has tripped. Check the motor Motor overtemperature Motor underload 22 Checksum error EEPROM The motor temperature model of the inverter has detected overheating of the motor. The motor is overloaded. The motor underload protection has tripped. Failed parameters recovery Malfunction Component fault Check the motor wiring and the motor. Remedy the fault and restart. If the fault recurs, contact our assistance centre In the case of temporary interruption of the power supply, reset the fault and restart the inverter. Check the power supply voltage. If OK, the problem is due to an internal fault Contact our assistance service. Check the motor wiring and the motor. Check that the quantity and flow rate of the cooling air is OK. Check that there is no dust buildup on the heat sink. Check the ambient temperature. Check that the commutation frequency is not too high relative to the ambient temperature and the load on the motor. Reduce the load on the motor. If the motor is not overloaded, check the temperature model parameters. Contact our assistance service. Page 47 of 60

48 CODE FAULT POSSIBLE CAUSE REMEDY 24 Counter fault 25 Watchdog faulty 29 Thermistor fault Internal communication bus IGBT temperature Panel communication fault The value displayed on the counter is incorrect. Malfunction Component fault The thermistor input on the optional board has detected an increase in the motor temperature. Environmental interference or defective hardware. The inverter IGBT bridge has detected an excessive overload current of brief duration. The connection between the control panel and the inverter is interrupted. Reset the fault and restart. If the fault recurs, contact our assistance centre Check the load and the cooling system. Check the thermistor connection (if the thermistor input of the optional board is not used it must be short-circuited). Reset the alarm and restart. If this alarm code reappears, contact our assistance service. Check the load Check the size of the motor Check the panel connection. Page 48 of 60